Turbo install sucks!

[freaktroll]

Boy, does this ever suck. My car is in the garage on jacks just waiting...
The DP turbo is a bitch to fit. I have no idea how Mrfancypants did it:confused:
Tapping the block just took wayyy to long as we had to find a drill bit that was small enough (3/8 drill bits that size are hard to find)... took us more than half the day to drill and tap, not to mention another almost full day to get the freaken oil pans off. They are like super glued to the block and have about 30 bolts holding them on. I havent even started on the IC piping, and Im using some jerry-rig to hold the IC on the bumper mount right now because there are no brackets on the IC (doh!).

Lets see, other things that went horribly wrong...

1. I dropped in the new injectors/ECU and went to set the fuel pressure, but the car wouldnt run long enough for me to adjust the FPR. Finally figured out the stupid FP gauge is wayyy off an the car was pig rich and choking. Took about half the day to finish what should have taken 2 hours max.

2. To get the manifold in, I had to disconnect this pipe running in front of it. After half a turn it started hissing like crazy for about a half hour. No more A/C! it was a compressor line and I just lost all the pressure in the A/C system (doh!)

3. Finally got the manifold to line up, but the wastegate actuator kept hitting the block and there was no way it could fit on the stock bracket. Luckly I boughtthis bracket (http://www.atpturbo.com/Merchant2/merchant.mvc?Screen=PROD&Product_Code=ATP-WGT-011&Category_Code=GTBB) way back, which is very nessecary for the install of the DP.
I ground down a bunch of the motor mount, but still wont fit, so I ordered a 1/2" manifold spacer to push it further away, which will also aid in the clearence for the turbo inlet as well.
The motor mount bracket is going to have to be butchered though no matter what.

Things that went right:
Nothing... well except for the fact that my 3" JGY mandrel downpipe will bolt directly up to the stock cat flange =) (yay!)
For those of you who think the catalytic converter is somehow restricting your system... its is a 3" High flow converter. Thats about twice the size of many parts of your exhaust (it reduces down to about 1.8" in many of the bends). What the heck did I buy a catco converter for?:nervous:

Well, hopefully I will have everything done (except for the exhaust system) by this weekend. It sucks only having one car between my wife and I.

What a freaken nightmare... it better be worth it!:lol:

Pics:
http://www.g20.net/gallery/data/504/547DSC00691.JPG

http://www.g20.net/gallery/data/504/547DSC00692.JPG

[Alex]

your car will be the perfect package (looks+speed) after this turbo gets thrown in there. damn. i want turbo now....

[P10Bostonian]

*drools* all of this turbo talk is gettin me excited. :nervous: lol... i wanna save up for turbo, maybe when i get out of college...

BTW how much is the ENTIRE set up gonna cost you. and how much if i have someone install it for me.

[MrFancypants]

Duuuuude... I feel your pain :) Oh the memories... brings a tear to my eye... :*(

If it makes you feel any better it will almost seem worth it once the car is boosting... almost :lol:

We were lucky bending the a/c line. It was a two man job (one person holding clamping the line at the connection to the compressor, the other pushing and bending the line) but no leaks!

Hopefully that manifold spacer will work -- told you it was tight!

You obviously never read any of my posts about the stock cat... I still run the stock cat ;)

I would rethink your intercooler placement if I were you. You should cut the bumper and slide the intercooler up behind it. You want the entire surface of the intercooler to be in front of the condensor/radiator. Right now youve got the lower radiator support behind it, which means NO flow through the lower 2-3" of the intercooler.

My prediction is youre still at this next week... but thats just from person experience! :lol:


- Greg -

[rich_3z]

I can see a nice write-up coming from freaktroll.....

Turbo setup???and cost??? I can already see the countless hours needed..... good thing your in my neighborhood if I ever decide to add a little boost on my p11:)


I think we might be looking at a preview of a future member of the month for sure.

clean and soon to be fast G!!!

[viet-g20]

im sure it will be all worth it in the end though....pshhhhh

[freaktroll]

Originally posted by MrFancypants

I would rethink your intercooler placement if I were you. You should cut the bumper and slide the intercooler up behind it. You want the entire surface of the intercooler to be in front of the condensor/radiator. Right now youve got the lower radiator support behind it, which means NO flow through the lower 2-3" of the intercooler.

- Greg -


Really? I was thinking that if it got enough surface area from the front, it would be ok. The intercooler is sitting a good inch or two from the support (when I modified the front bumper, I cut a good chunk out from the center allowing the IC to be mounted right at the edge of the bumper, so I figured the flow would not be inhibited at all.
Im not too versed in airflow dynamics though, so would I still get no flow even if the front of the IC is fully exposed, and the back is a good 1 or 2 inches from any solid structure?

[freaktroll]

Originally posted by P10Bostonian
BTW how much is the ENTIRE set up gonna cost you. and how much if i have someone install it for me.

Jeez.. I really dont know exactly... you can go alot of different ways and get varing prices, but for me....probably when all is said and done, around $5-6k? for just parts...DIY install ;). The price may seem a bit high, but for gauges, injectors, studs (more than $100 in studs :confused:) full exhaust, piping, intercooler, DP turbo, oil lines, all the fittings, clutch, tranny oil, boost controller, BOV, manifold, etc... it gets pretty pricy. I think places usally charge about $800 or so for a turbo install, I think that is including the I/C pipe fabricating.

Originally posted by rich_3z
I can see a nice write-up coming from freaktroll.....

Turbo setup???and cost??? I can already see the countless hours needed..... good thing your in my neighborhood if I ever decide to add a little boost on my p11:)



Writeup?? uh, probably not, well not too detailed at least. It was such a pain in the butt, all you are trying to do is get through it.. get it done. No time for pictures and notes;)
I will detail the entire setup a bit later once I can figure out what all I got :lol:

[P10Bostonian]

Originally posted by freaktroll


Jeez.. I really dont know exactly... you can go alot of different ways and get varing prices, but for me....probably when all is said and done, around $5-6k? for just parts...DIY install ;). The price may seem a bit high, but for gauges, injectors, studs (more than $100 in studs :confused:) full exhaust, piping, intercooler, DP turbo, oil lines, all the fittings, clutch, tranny oil, boost controller, BOV, manifold, etc... it gets pretty pricy. I think places usally charge about $800 or so for a turbo install, I think that is including the I/C pipe fabricating.



Writeup?? uh, probably not, well not too detailed at least. It was such a pain in the butt, all you are trying to do is get through it.. get it done. No time for pictures and notes;)
I will detail the entire setup a bit later once I can figure out what all I got :lol:

Yikes!!1 twice the price i paid for my car... is it possible to put it in a 93 p10?


and as for your write up, it should only have 2 words.



GOODLUCK

[TurboG20]

I know the feeling. I can be frustrating. My car was up on jacks for over a month getting everything installed - and that was *after* relocating the battery, installing the manifold, downpipe, ECU, injectors, clutch and building a new exhaust.

When we fired it up for the first time, the car idled like crap 'cause the MAF adaptor didn't line up properly causing turbulence over the sensor. Half a day blown. We fixed that but the engine sounded like a jackhammer - all the oil leaked out of the hydraulic lash adjusters. A day blown, and it scared the hell out of me. We kept running out of clamps, breaking tools, and having to make "just one more argon run" for the welder, burning up huge amounts of time.

...then after driving around for a couple of months, I upgraded the turbo, and melted a piston.

Having a boosted car definitely kicks ass, but you've got to like the build-up stage as well, even if it sucks at times. From what I've experienced, you are never done working on the car once you modify it this heavily.

[MrFancypants]

Im not too versed in airflow dynamics though, so would I still get no flow even if the front of the IC is fully exposed, and the back is a good 1 or 2 inches from any solid structure?

Well as long as you have a clear path for air to make it through the intercooler, you should be okay.

I wanted mine mounted right in front of the condensor so that when the fans kick on it pulls air through everything -- intercooler included. I sealed all the gaps with foam weather stripping to further direct air. In actuality the car only sees boost while youre moving, so getting anal about the fans is just... well it's anal.

I also didnt want to modify my front bumper cover because I wanted the car to still look stock(ish). That meant flush mounting it to the lower radiator support. Still, it sounds like you thought things through.

Definitely pay very close attention to your MAF wiring. I spent a ridiculous amount of time wiring in my Cobra MAF (soldering, shielding, taping, etc.), but never had any problems with it. A friend of mine rigged his together really quick and his car ran like shit until he redid everything.

Hey quit reading this and get back in your garage already :lol:


- Greg -

[rich_3z]

Writeup doesnt have to be detailed......

Parts = $5-6,000
Labor = DIY or $800

Driving a G20 Turbo = PRICELESS!!!!!!

[B-G20]

it might be a pain in the ass now..but just think of the rewards...i'm jealous

[CarloSR]

Good luck man,

[Yahnozha]

Damn those are some good looking H20 Adapters :lol:

[daveyourself]

don't despair. go slow and take your time, you don't want to have to go back in there later.
it'll all work out.

[m5dssm5]

what are you gonna do w/ the ECU?
if order from JWT better do it now, b/c it takes them forever to get one to you.

for my intercooler the bumper support had to be cut a bit b/c otherwise you'll be banging your intercooler in every dip.

all in all, thank god i got a det, and not went with the turbo.

[akuma810]

this is great!

pictures are worth a thousand words ;)